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Ezgo TERRAIN 250 Service Manual

Ezgo TERRAIN 250
208 pages
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625610
625617
ISSUED MAY 2012 REVISED AUGUST 2012
GASOLINE POWERED UTILITY VEHICLE
TECHNICIAN’S REPAIR AND SERVICE MANUAL

Table of Contents

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Ezgo TERRAIN 250 Specifications

General IconGeneral
BrandEzgo
ModelTERRAIN 250
CategoryUtility Vehicle
LanguageEnglish

Summary

SAFETY

SAFETY SYMBOLS AND GENERAL WARNINGS

Defines safety symbols and provides general safety advice for vehicle operation and maintenance.

SAFETY DEFINITIONS AND WARNINGS

Explains safety notices, cautions, warnings, dangers, and pre-servicing safety precautions.

HAZARDOUS MATERIALS AND ENVIRONMENTAL SAFETY

Details safety warnings for fuel, batteries, and awareness of carbon monoxide hazards.

BATTERY SERVICE AND VEHICLE LIFTING

Covers battery removal/installation safety and critical procedures for lifting the vehicle.

VEHICLE LIFTING PROCEDURE

Provides detailed instructions and safety precautions for lifting the vehicle securely.

SAFETY INFORMATION

GENERAL INFORMATION & ROUTINE MAINTENANCE

PERIODIC SERVICE SCHEDULE

Outlines the recommended schedule for regular vehicle maintenance tasks.

FRONT SUSPENSION AND STEERING

FRONT SUSPENSION AND AXLE MOUNTED STEERING

SPEED CONTROL

ROAD TEST PROCEDURE

Provides instructions for conducting a road test to verify speed control system performance.

ENGINE

POWERTRAIN MAINTENANCE AND OIL LEVEL CHECK

Covers powertrain maintenance and the procedure for checking engine oil level.

OIL CHANGE AND ENGINE CLEANING

Details the process for changing engine oil and cleaning the engine exterior.

ENGINE SPECIFICATIONS AND COMPRESSION MEASUREMENT

Provides engine specifications and the procedure for compression measurement.

CYLINDER HEAD SERVICE PROCEDURES

Covers rocker cover removal, valve clearance inspection, and adjustment.

ENGINE INSTALLATION AND DRIVE CLUTCH REMOVAL

Covers engine installation and drive clutch removal procedures.

FUEL SYSTEM

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

DRIVE CLUTCH REMOVAL PROCEDURE

Provides the step-by-step process for removing the drive clutch.

DRIVE CLUTCH REMOVAL

Details the procedure for removing the drive clutch assembly.

DIRECTION SELECTOR

ELECTRICAL

MAGNETO TESTING PROCEDURES

Provides resistance testing procedures for the magneto.

STARTING AND CHARGING CIRCUIT TESTING

Details procedures for testing the starting and charging circuits of the vehicle.

STARTER/GENERATOR REPAIR AND BATTERY TEST

Details repair/replacement procedures for starter/generator and battery voltage testing.

BATTERY VOLTAGE TEST, DVOM USAGE, AND TROUBLESHOOTING

Covers battery testing, DVOM usage, and general troubleshooting for electrical issues.

BATTERY CONDITION, WIRE, AND FUSE CHECKS

Covers checking battery condition, wires, and fuses within the electrical system.

MECHANICAL BRAKES

BRAKE SYSTEM TROUBLESHOOTING TABLE

A table listing common brake system issues, possible causes, and corrections.

BRAKE SYSTEM INSPECTION PROCEDURES

Covers inspection of the brake pedal, linkage, and free travel.

BRAKE PEDAL FREE TRAVEL AND LINKAGE INSPECTIONS

Covers checking pedal free travel, clevis pins, equalizer linkage, compensator, and parking brake hinge.

PERIODIC BRAKE PERFORMANCE TEST (PBPT)

Outlines the procedure for performing a periodic brake performance test.

AGGRESSIVE STOP TEST

Details the procedure for conducting an aggressive stop test for brake evaluation.

WHEEL BRAKE INSPECTION

Provides procedures for inspecting wheel brake components.

CHECK BRAKE PEDAL FREE TRAVEL

Procedure for checking and adjusting the brake pedal's free travel.

WHEEL BRAKE SERVICE

Covers disassembly, cleaning, inspection, and re-assembly of wheel brake assemblies.

BRAKE SHOE AND ADJUSTER REPLACEMENT

Details the procedure for replacing brake shoes and adjuster components.

CHECK THE BRAKE PEDAL FREE TRAVEL

Details the procedure for checking and adjusting the brake pedal's free travel.

CHECK/ADJUST BRAKE PEDAL FREE TRAVEL

Procedure for checking and adjusting the brake pedal free travel.

ADJUSTING BRAKE PEDAL FREE TRAVEL

Detailed procedure for adjusting the brake pedal free travel.

REAR SUSPENSION

REAR AXLE

CHECKING THE LUBRICANT LEVEL

Provides the procedure for checking and maintaining the rear axle lubricant level.

TROUBLESHOOTING

GASOLINE VEHICLE PERFORMANCE

Troubleshooting guide for gasoline vehicle performance issues.

ENGINE RUNS ROUGH OR LOSS OF POWER

Troubleshooting steps for an engine that runs rough or has lost power.

REPEATED SPARK PLUG FOULING

Troubleshooting steps for recurring spark plug fouling issues.

ERRATIC, SURGING, OR SUDDEN CHANGE IN GOVERNED SPEED

Troubleshooting steps for erratic speed, surging, or sudden changes in governed speed.

STEERING PULLS TO ONE SIDE

Troubleshooting steps for steering that pulls to one side.

NEITHER WHEEL LOCKS WHEN PARK BRAKE IS LATCHED

Troubleshooting steps when neither wheel locks with the parking brake engaged.

STARTER DOES NOT TURN

Troubleshooting steps when the starter motor does not engage.

POOR MIDRANGE OR HIGH SPEED PERFORMANCE

Troubleshooting steps for poor performance at midrange or high speeds.

CARBURETOR FLOODS ENGINE

Troubleshooting steps when the carburetor floods the engine.

FUEL ACCUMULATION IN THE CRANKCASE

Troubleshooting steps for fuel accumulation in the crankcase.

CARBURETOR

Troubleshooting guide for common carburetor problems.

BRAKE SYSTEM

Troubleshooting guide for common brake system problems.

UNEQUAL BRAKING (ONE WHEEL LOCKS WHILE OTHER ROTATES)

Troubleshooting steps for unequal braking where one wheel locks and the other rotates.

STARTER TURNS SLOWLY

Troubleshooting steps when the starter motor turns slowly.

ENGINE OVERHEATING

Troubleshooting steps for an overheating engine.

EXCESSIVE SMOKING

Troubleshooting steps for excessive smoke from the engine.

OVERFLOW/LEAK

Troubleshooting steps for carburetor overflow or leaks.

FAILS BRAKE PERFORMANCE TEST BY STOPPING IN LONGER DISTANCE THAN NORMAL

Troubleshooting for brake performance test failures (longer stopping distance).

NEITHER WHEEL LOCKS

Troubleshooting steps when neither wheel locks.

STARTER ROTATES BUT VEHICLE WILL NOT START OR HARD TO START

Troubleshooting steps when the starter engages but the engine fails to start.

POOR LOW SPEED PERFORMANCE

Troubleshooting steps for poor performance at low speeds.

BACKFIRING

Troubleshooting steps for engine backfiring issues.

IN EXCESS OF 1" (2.5 CM) FREE PEDAL TRAVEL (SOFT PEDAL)

Troubleshooting steps for excessive free pedal travel (soft pedal).

GRABBING BRAKES (OVERSENSITIVE)

Troubleshooting steps for brakes that grab or are oversensitive.

POOR FUEL ECONOMY

Troubleshooting steps for poor fuel economy.

LESS THAN 3/4" (1.9 CM) FREE PEDAL TRAVEL (HARD PEDAL)

Troubleshooting steps for insufficient free pedal travel (hard pedal).

PARKING BRAKE HARD TO LATCH

Troubleshooting steps for a parking brake that is hard to latch.

POOR ACCELERATION

Troubleshooting steps for poor acceleration.

PARKING BRAKE WILL NOT STAY LATCHED

Troubleshooting steps when the parking brake does not stay latched.

HARD STARTING

Troubleshooting steps for difficulty starting the engine.

STARTER IS NOISY

Troubleshooting steps for a noisy starter/generator.

GENERAL SPECIFICATIONS

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